Electric vehicle charging connector

Abstract

An electrical connector includes a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables, a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities. The plurality of cover cavities is configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities.

The invention claimed is: 
     
       1. An electrical connector, comprising:
 a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables; 
 a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, wherein the housing includes a printed circuit board assembly defining a plurality of circuit board apertures through which the plurality of cylindrical electrical terminals extends; and 
 a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities, the plurality of cover cavities configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities. 
 
     
     
       2. The electrical connector according to  claim 1 , further comprising a terminal seal configured to provide an environmental seal between the plurality of cylindrical electrical terminals and the cover, the terminal seal disposed between the housing and the cover. 
     
     
       3. The electrical connector according to  claim 1 , further comprising a plurality of terminal retainers surrounding the plurality of first electrical cables configured to cooperate with the plurality of cover cavities to hold the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities. 
     
     
       4. The electrical connector according to  claim 3 , further comprising a plurality of first cable seals surrounding the plurality of first electrical cables configured to provide an environmental seal between the plurality of first electrical cables, the plurality of terminal retainers, and inner walls of the plurality of cover cavities. 
     
     
       5. The electrical connector according to  claim 3 , further comprising a yoke configured to separate the plurality of first electrical cables and configured to secure the plurality of terminal retainers within the plurality of cover cavities. 
     
     
       6. The electrical connector according to  claim 1 , wherein the cover defines a plurality of cover terminal cavities configured to receive a plurality of planar electrical terminals attached to a plurality of second electrical cables and wherein the plurality of planar electrical terminals is attached to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners. 
     
     
       7. The electrical connector according to  claim 6 , wherein one planar electrical terminal of the plurality of planar electrical terminals is laterally and longitudinally offset from another planar electrical terminal of the plurality of planar electrical terminals. 
     
     
       8. The electrical connector according to  claim 6 , wherein the cover defines an access portal located, sized, and arranged to allow tool access to the plurality of threaded fasteners. 
     
     
       9. The electrical connector according to  claim 8 , further comprising a plurality of second cable seals surrounding the plurality of second electrical cables configured to provide an environmental seal between the plurality of second electrical cables and inner walls of the plurality of cover terminal cavities. 
     
     
       10. The electrical connector according to  claim 9 , further comprising a plurality of second cable retainers configured to hold the plurality of second cable seals within the plurality of cover terminal cavities. 
     
     
       11. The electrical connector according to  claim 9 , further comprising a removeable access plug configured to seal the access portal. 
     
     
       12. The electrical connector according to  claim 6 , wherein the cover may be configured to dress the plurality of first electrical cables and the plurality of second electrical cables in a rightward direction, in a leftward direction, or in a downward direction. 
     
     
       13. The electrical connector according to  claim 1 , wherein the printed circuit board assembly includes a connector header and wherein the connector header is sealed to the cover. 
     
     
       14. A method of assembling an electrical connector, comprising:
 inserting a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables into plurality of housing terminal cavities of a connector device having a housing defining the plurality of housing terminal cavities and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities, wherein the plurality of cover cavities receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities; and 
 inserting the plurality of cylindrical electrical terminals through a plurality of circuit board apertures defined by a printed circuit board assembly disposed within the housing. 
 
     
     
       15. The method of  claim 14 , further comprising:
 attaching a plurality of terminal retainers to the plurality of first electrical cables, wherein the plurality of first electrical cables cooperates with the plurality of cover cavities to hold the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities. 
 
     
     
       16. The method of  claim 14 , further comprising:
 inserting a plurality of planar electrical terminals attached to a plurality of second electrical cables within a plurality of cover terminal cavities defined by the cover; and 
 attaching plurality of planar electrical terminals to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners. 
 
     
     
       17. The method of  claim 16 , further comprising:
 laterally and longitudinally offsetting one planar electrical terminal of the plurality of planar electrical terminals from another planar electrical terminal of the plurality of planar electrical terminals. 
 
     
     
       18. The method of  claim 17 , further comprising:
 inserting a removeable access plug into an access portal located, sized, and arranged to allow tool access to the plurality of threaded fasteners.